US10016311B2 - Elastic contained within a jointly folded top cover and bottom cover and process of making - Google Patents

Abstract

An absorbent article is disclosed. The absorbent article is a pad that includes a top cover and a lower baffle. The absorbent article also includes a shaping element. The shaping element is folded within the top cover and the absorbent article. The fold is directed toward the baffle. The top cover therefore forms a terminal seam on the lower surface of the baffle. A process is also disclosed. The process includes folding the shaping element into the edges of the top cover and the baffle as the top cover and the baffle form a single fold.

Description

TECHNICAL FIELD

Embodiments relate to an article for receiving a liquid. More particularly, embodiments relate to an article for receiving a liquid that is shaped by an elastic shaping element. In particular, an article for receiving a liquid includes a shaping element that is enfolded into both the top cover and the bottom cover.

TECHNICAL BACKGROUND

Many articles used as incontinent products or menstrual pads have been found unsatisfactory as they are bulky and/or ineffective. Many such garments are formed by forming flat sheets into a diaper-like structure for incontinent use. Other pads for catamenial use have been formed in thin flat structures, but these structures have been low in absorption. Further, flat structures have a tendency to wrinkle between the legs during use causing discomfort and distorting the target area where the exudate will be located.

Small elasticized pads have been developed in which an elasticized sanitary napkin is employed. The sanitary napkin has elastic threads that are imbedded in the napkin, running in the long direction of the napkin. Other small elasticized pads have been developed in which a sanitary napkin having elasticized edges and a raised center portion are employed. However, these pads have not found wide acceptance as they are bulky and do not fit the female form to provide both comfort and absorbency.

It has been known in the diaper art to provide diapers that are shaped by having elastic at the edges. However, diaper-like structures are not suitable for use as a catamenial napkin, or for use as an absorbent member for an adult with mild urinary incontinence. They are too large, bulky, and obtrusive to be suitable for such use.

Therefore, there remains a need for a napkin for catamenial and urinary incontinence use that will not bunch during walking and is comfortable.

SUMMARY

An article is disclosed that includes a liquid-permeable top cover and a liquid-impermeable bottom cover. The bottom cover is also referred to as a baffle. Together, the liquid-permeable top cover and the liquid-impermeable bottom cover form an envelope. In one embodiment, at least one of the top cover and the bottom cover includes a terminal edge under the article. The article is also referred to as a pad.

A shaping element is operatively associated with the top cover and the bottom cover. The top cover and the bottom cover are folded over the shaping element. In other words, the shaping element is enfolded with the top cover and the bottom cover in a direction toward the exterior surface of the bottom cover.

An absorbent first element is enclosed by the top cover and the bottom cover. The absorbent first element is a liquid-absorbing medium such as is used in the personal care products arts.

In the personal care products art, the top cover is presented against the user and the bottom cover is presented against the user's clothing such as the user's underwear.

In one embodiment, the shaping element is first secured to the bottom cover, within the fold, by a shaping element adhesive, and second contained within a seam between the top cover and the bottom cover by a construction adhesive. According to an embodiment, since at least one of the top cover and the bottom cover terminates under the pad, the seam likewise is located under the pad.

In one embodiment, the pad curls into an arcuate shape due to the presence of the shaping element when it is allowed to recoil. Additionally, a gathered portion of at least one of the top cover and the bottom cover, forms along the occurrence of the shaping element.

In one embodiment, at least one subsequent shaping element is provided adjacent the first shaping element, and within the fold of the top cover and the bottom cover.

A process is also disclosed. The process includes providing a top cover, providing a bottom cover, and providing a shaping element according to the various article embodiments set forth in this disclosure. The process includes folding the top cover and the bottom cover, in a single fold, after a manner that causes the shaping element to be enfolded with the top cover and the bottom cover in a direction toward the lower exterior surface of the bottom cover.

These and other embodiments are set forth more fully in the balance of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the manner in which embodiments are obtained, a more particular description of various embodiments briefly described above will be rendered by reference to the appended drawings. Understanding that these drawings depict only typical embodiments that are not necessarily drawn to scale and are not therefore to be considered to be limiting of its scope, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a cross section of a pad according to an embodiment;

FIG. 2A is a cross section of a pad according to an embodiment;

FIG. 2B is a side elevation of the pad depicted inFIG. 2A;

FIG. 3 is partial cut-away perspective elevation of a pad;

FIG. 4 is a cross section of a pad according to another embodiment;

FIG. 5 is a cross section of a pad according to another embodiment;

FIG. 6 is a cross section of a pad according to another embodiment;

FIG. 7 is a cross section of a pad according to another embodiment;

FIG. 8 is a cross section of a pad according to another embodiment;

FIGS. 9A-9C are cross-section details of a shaping element or shaping elements according to various embodiments; and

FIG. 10 is a process flow diagram according to an embodiment.

DETAILED DESCRIPTION

The following description includes terms, such as first, second, etc. that are used for descriptive purposes only and are not to be construed as limiting. In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. These drawings show, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, some of the like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be used and structural changes may be made without departing from the scope of the several embodiments.

FIG. 1 is a cross section of a pad according to an embodiment. Thepad100 is in an exploded configuration for clarity. Thepad100 includes a liquid-permeabletop cover110 and a liquid-impermeable bottom cover112. Thebottom cover112 is also referred to as a baffle. Together, the liquid-permeabletop cover110 and the liquid-impermeable bottom cover112 form an envelope. In one embodiment, at least one of thetop cover110 and thebottom cover112 terminates under thepad100. An absorbentfirst element114 is enclosed by thetop cover110 and thebottom cover112. The absorbentfirst element114 is a liquid-absorbing medium such as is used in the personal care products arts.

In one embodiment, thetop cover110 is compliant, soft feeling, and non-irritating to the wearer's skin. Additionally, thetop cover110 is liquid pervious to permit liquids to penetrate through its thickness. In one embodiment, thetop cover110 is manufactured from a wide range of materials such as woven and non-woven materials. In one embodiment, thetop cover110 is derived from polymeric materials such as apertured formed thermoplastic films, apertured plastic films, hydroformed thermoplastic films, and the like. In one embodiment, thetop cover110 is derived from porous foams and the like. In one embodiment, thetop cover110 is derived from reticulated foams and the like. In one embodiment, thetop cover110 is derived from reticulated thermoplastic films and the like. In one embodiment, thetop cover110 is derived from thermoplastic scrims and the like.

Suitable woven and non-woven material embodiments include natural fibers such as wood or cotton fibers and the like. Other suitable woven and non-woven material embodiments include synthetic fibers such as polymeric fibers including polyester, polypropylene, polyethylene fibers, and the like. Other suitable woven and non-woven material embodiments include a combination of natural and synthetic fibers.

In one embodiment, thetop cover110 includes an apertured formed film. An apertured formed film is pervious to body exudates and yet it is non-absorbent and has a reduced tendency to allow liquids to pass back through and re-wet the wearer's skin. Thus, the surface of the formed film which is in contact with the body remains dry, thereby reducing body soiling and creating a more comfortable feel for the wearer.

In one embodiment, the body surface of thetop cover110 is hydrophilic so as to help liquid to transfer through thetop cover110 faster than if the body surface was not hydrophilic so as to diminish the likelihood that fluid will flow off thetop cover110 rather than flowing into and being absorbed by the absorbent core. In one embodiment, surfactant is incorporated into the polymeric materials of thetop cover110.

Thebottom cover112 is impervious to liquids and in one embodiment, is manufactured from a thin plastic film, although other flexible liquid impervious materials can also be used. As used herein, the term “flexible” refers to materials which are compliant and will readily conform to the general shape and contours of the human body. Thebottom cover112 prevents the exudates absorbed and contained in the absorbentfirst element114 from wetting articles which contact the sanitary napkin such as pants, pajamas and undergarments. In one embodiment, thebottom cover112 includes at least one of a woven or non-woven material, polymeric films such as thermoplastic films of polyethylene or polypropylene, or composite materials such as a film-coated non-woven material. In one embodiment, thebottom cover112 is a polyethylene film having a thickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils). In one embodiment, thebottom cover112 permits vapors to escape from the absorbentfirst element114 while still preventing exudates from passing through thebottom cover112.

In another embodiment, thetop cover110 is referred to as atop cover110 including a first liquid permeability. Thebottom cover112 includes a second liquid permeability. In this embodiment, the first liquid permeability is greater than the second liquid permeability. In one embodiment, thebottom cover112 is porous, but it has at least one of an average pore size or a hydrophobicity which resists the pass-through flow of a liquid that is contemplated for ordinary use. In this embodiment, thebottom cover112 is substantially liquid impermeable.

In one embodiment, the envelope of thetop cover110 and thebottom cover112 are referred to as a web. In one embodiment, the web can contain various elements as will be set forth in this disclosure. In one embodiment, the web is an adult care garment precursor or the like, such as for a DEPEND® product or the like, made by Kimberly-Clark Corporation of Neenah, Wis. In one embodiment, the web is a feminine care garment precursor or the like, such as for a KOTEX® product or the like, also made by Kimberly Clark Corporation. In one embodiment, the web is an infant care garment precursor or the like, such as for a HUGGIES® product or the like also made by Kimberly-Clark Corporation. In one embodiment, the web is a childcare garment precursor or the like, such as for a PULL-UPS® product or the like, also made by Kimberly-Clark Corporation. In one embodiment, the web is a non-woven web precursor or the like, such as for a KLEENEX® product or the like, also made by Kimberly-Clark Corporation. In one embodiment, the web is a woven web precursor or the like. By reading this disclosure, it becomes clear that another embodiment includes a “web” that is any other material that is conducive to being processed according to the various embodiments set forth in this disclosure.

In one embodiment, the absorbentfirst element114 is any absorbent material which is capable of absorbing or retaining liquids. In one embodiment, the absorbentfirst element114 is manufactured in a wide variety of sizes and shapes (e.g., rectangular, oval, hourglass, dog bone, asymmetric, etc.) and from a wide variety of liquid-absorbent materials commonly used in absorbent napkins and other absorbent articles such as comminuted wood pulp which is generally referred to as airlaid.

In one embodiment, the absorbentfirst element114 includes creped cellulose wadding and the like. In one embodiment, the absorbentfirst element114 includes dmeltblown polymers including coform and the like. In one embodiment, the absorbentfirst element114 includes chemically stiffened, modified or cross-linked cellulosic fibers and the like. In one embodiment, the absorbentfirst element114 includes synthetic fibers such as crimped polyester fibers and the like. In one embodiment, the absorbentfirst element114 includes peat moss and the like. In one embodiment, the absorbentfirst element114 includes tissue including tissue wraps and tissue laminates and the like. In one embodiment, the absorbentfirst element114 includes absorbent foams and the like. In one embodiment, the absorbentfirst element114 includes absorbent sponges and the like. In one embodiment, the absorbentfirst element114 includes superabsorbent polymers and the like. In one embodiment, the absorbentfirst element114 includes absorbent gelling materials and the like. In one embodiment, the absorbentfirst element114 includes combinations of materials, or mixtures of these.

The configuration and construction of the absorbentfirst element114 can also be varied (e.g., the absorbent core can have varying caliper zones such profiled zones (not pictured) so as to be thicker in the center. In one embodiment, the absorbentfirst element114 includes a hydrophilic gradient. In one embodiment, the absorbentfirst element114 includes a superabsorbent gradient. In one embodiment, the total absorbent capacity of the absorbentfirst element114 is compatible with the design loading and the intended use of thepad100. In one embodiment, the size and absorbent capacity of the absorbentfirst element114 can be varied to accommodate different uses such as incontinence pads, pantiliners, regular sanitary napkins, or overnight sanitary napkins.

Afirst shaping element116 is operatively associated with thetop cover110 and thebottom cover112. By “operatively associated”, it is meant that thetop cover110 and thebottom cover112 are folded over thefirst shaping element116. The fold is directed downwardly as depicted inFIG. 1 in the negative-Z direction. In other words, thefirst shaping element116 is enfolded with thetop cover110 and thebottom cover112 in a direction toward thebottom cover112.

In one embodiment, thetop cover110 is presented against the user in the positive-Z direction, and thebottom cover112 is presented against the user's clothing such as the user's underwear. In one embodiment, thefirst shaping element116 is deployed under tension along the Y-axis (seeFIG. 3), and it is tensed in order to cause thepad100 to curl upwardly in the in the positive-Z direction.

In one embodiment, thefirst shaping element116 is first secured to thebottom cover112 by a shaping element adhesive118, and second contained within aseam120 between thetop cover110 and thebottom cover112, by aconstruction adhesive122. According to an embodiment, since at least one of thetop cover110 and thebottom cover112 terminates under thepad100, theseam120 likewise is located under thepad100.

In one embodiment, the shaping element adhesive118 is deployed by intermittent depositions along thepad100 along the Y-axis (seeFIG. 3). An intermittent deposition allows at least one of thetop cover110 and thebottom cover112 to form a gathered structure that can allow a substantially uniform pucker along the Y-axis of the pad100 (seeFIG. 2B). In one embodiment, a continuous adhesive deposition along thepad100 is carried out.

Deposition of the shaping element adhesive118 can be done by various processes. In one embodiment, the shaping element adhesive118 is air-deposited by a process selected from spraying, meltblowing, swirling, and combinations thereof according to conventional technique. In one embodiment, the shaping element adhesive118 is contact-deposited by a process selected from slot, bead, Gravure coating, and combinations thereof according to conventional technique.

In one embodiment, the adhesive delivered by the adhesive applicator is any suitable material that can attach thefirst shaping element116 to thebottom cover112. In one embodiment, the adhesive secures aplastic bottom cover112 to an elastomericfirst shaping element116. Such an adhesive is known in the art. In one embodiment, the adhesive is a water-based composition that is pressure sensitive such as an acrylate adhesive or the like. In one embodiment, the adhesive is a thermoplastic composition that is used to thermally weld structures together. In one embodiment, the thermoplastic adhesive is H2840, manufactured by Findley Adhesives of Wauwatosa, Wis. In one embodiment, the thermoplastic adhesive is NS 34-5610 manufactured by National Starch of Bridgewater, N.J. In one embodiment, the adhesive is a double-sided film such as a double-sided tape, as known in the art.

FIG. 2A is a cross section of a pad according to an embodiment. Thepad200 is depicted in a simplified, schematic view. Thepad200 includes a liquid-permeabletop cover210 and a liquid-impermeable bottom cover212. Thebottom cover212 is also referred to as a baffle. Together, the liquid-permeabletop cover210 and the liquid-impermeable bottom cover212 form an envelope. In one embodiment, at least one of thetop cover110 and thebottom cover212 terminates against thebottom cover212. An absorbentfirst element214 is enclosed by thetop cover210 and thebottom cover212. The absorbentfirst element214 is a liquid-absorbing medium such as is used in the personal care products arts.

FIG. 2A depicts one embodiment where theseam220 between the edge of thetop cover210 and a portion of thebottom cover212 have also been drawn into the Z-direction and thepad200 has partially deflected in a region proximate thefirst shaping element216.

FIG. 2B is a side elevation of the pad depicted inFIG. 2A. The depiction inFIG. 2B represents the effect of thefirst shaping element216 as it recoils. Thereby, a portion of each of thetop cover210 andbottom cover212, each containing thefirst shaping element216, are drawn into the Z-direction. The portion of thepad200 that includes the absorbentfirst element214 remains relatively unaffected when viewed in this cross section.

In one embodiment, thepad200 is a side elevation of thepad100 depicted inFIG. 1, but not in an exploded configuration. Thepad200 is depicted as curling into an arcuate shape in the Z-direction due to the presence of thefirst shaping element216 when it is allowed to recoil. Thepad200 also depicts thetop cover210, thebottom cover212, and theseam220 therebetween when the seam is drawn also into the Z-direction when thepad200 has partially deflected in a region proximate thefirst shaping element216. Theseam220 is analogous to theseam120 depicted inFIG. 1, but the portion of thepad200 that enfolds the first shaping element (not pictured) has folded upwardly in the Z-direction. Accordingly, theseam220 is revealed in a side elevation.

Additionally,FIG. 2B depicts a gatheredportion224 of at least one of thetop cover210 and thebottom cover212. In one embodiment, because the first shaping element (not pictured) is fastened to thebottom cover212 by intermittent depositions of the shaping element adhesive118 (FIG. 1), the gatheredportion224 forms a substantially uniform pucker. In one embodiment, a continuous adhesive deposition along thepad200 is carried out.

In one embodiment, the first shaping element216 (FIG. 2A) is variably tensed along its length. In this embodiment, shaping is controlled to be either along the entire length of thepad200, or in a portion thereof. In one embodiment, the shapingelement216 causes only a portion of the ends of the pad to curl upwardly in the Z-direction.

Reference is again directed toFIG. 1. In one embodiment, thefirst shaping element116 is an organic elastomeric material. An “elastomeric material” is understood to be a material that tends to recover its original size and shape after the removal of a deformational force. In one embodiment, an “elastomeric material” is a material that can be elongated greater than at least one-fourth its original dimension, and can recover toward its original dimension at by least one-tenth.

In one embodiment, thefirst shaping element116 is made of fluid permeable materials. In one embodiment, thefirst shaping element116 is made of a wet-spun elastomeric material. In one embodiment, thefirst shaping element116 is an extruded, hot-melt elastomeric adhesive. In one embodiment, thefirst shaping element116 is an adhesive elastomeric foam. In one embodiment, thefirst shaping element116 is a stretchable film.

In one embodiment, thefirst shaping element116 is an elastic material such as LYCRA® manufactured by E.I. du Pont de Nemours and Company of Delaware. In one embodiment, thefirst shaping element116 is a rigid material. In one embodiment, thefirst shaping element116 is a stiff member that imparts sufficient rigidity to thepad100 to cause a selected shape to form.

In one embodiment, thefirst shaping element116 is merely fullness of the web that forms at least one of thetop cover110 and thebottom cover112 as it is processed. In this embodiment, the fullness in the web can be formed by gathering and fastening the web to itself by various methods known in the art such as by a folding and intermeshing by a perforation process, a thermal welding process, or a gluing process. Further, the recoil experienced in thepad100 is the flexible nature of at least one of thetop cover110 and thebottom cover112.

In one embodiment, the first shaping element is a combination of at least one of an elastic member, a rigid member, a gathered portion of at least one of thetop cover110 and thebottom cover112, and a combination thereof.

In one embodiment, asurge element126 is disposed above the absorbentfirst element114. In one embodiment, thesurge element126 is employed for extra liquid-absorption capabilities. Thesurge element126 acts as a liquid intake and distribution layer. Thepad100 also includes a top cover adhesive128 that can make contact with thesurge element126 if present, the absorbentfirst element114, and thebottom cover112. In one embodiment, the top cover adhesive128 is formed in a swirl pattern, as is known in the art, to allow fluid to penetrate into thesurge element126 and the absorbentfirst element114. Thepad100 also includes a baffle adhesive130 that secures thebottom cover112 to the absorbentfirst element114. Thepad100 also includes agarment adhesive132 and arelease layer134 that protects thegarment adhesive132 prior to deployment.

FIG. 3 is a partial cut-away perspective elevation of apad300 that is presented in a simplified view for clarity. In one embodiment, thepad300 is presented in a flat configuration. Thepad300 includes a liquid-permeabletop cover310 and a liquid-impermeable bottom cover312. Together, the liquid-permeabletop cover310 and the liquid-impermeable bottom cover312 form an envelope. Afirst shaping element316 is operatively associated with thetop cover310 and thebottom cover312.

Thepad300 is configured such that a portion of thetop cover310 and thebottom cover312 are folded over thefirst shaping element316.FIG. 3 also depicts hidden elements. In phantom lines, theterminal edge311 of thetop cover310 is shown to form aseam320 against thebottom cover312. Further, theterminal edge313 of thebottom cover312 is also depicted, as well as thehidden portion317 of thefirst shaping element316 as it is deployed substantially parallel to the Y-axis.

In another embodiment, thepad300 is deployed along a symmetry line301 and theterminal edge311 of thetop cover310 terminates at a first coordinate303 along the X-axis at a first distance from the symmetry line301. Similarly, theterminal edge313 of thebottom cover312 terminates at a second coordinate305 along the X-axis at a second distance from the symmetry line301.

Although the embodiment depicted inFIG. 3 illustrates the first coordinate303 being farther from the symmetry line301 than the second coordinate305, another embodiment (not pictured) includes the opposite, such that theedge313 of thebottom cover312 terminates closer to the symmetry line301 than theterminal edge311 of the top cover. In yet another embodiment, theterminal edges311 and313, respectively, terminate (not pictured) at substantially the same distance from the symmetry line301. Similarly, one embodiment (not pictured) includes theedge313 of thebottom cover312 terminating the same distance to the symmetry line301 as theterminal edge311 of the top cover.

FIG. 4 is a cross section of a pad according to another embodiment. Thepad400 includes elements and structures similar to thepad100 depicted inFIG. 1. Thepad400 is in an exploded configuration for clarity. Thepad400 includes a liquid-permeabletop cover410 and a liquid-impermeable bottom cover412. Together, the liquid-permeabletop cover410 and the liquid-impermeable bottom cover412 form an envelope. An absorbentfirst element414 is enclosed by thetop cover410 and thebottom cover412. Afirst shaping element416 is operatively associated with thetop cover410 and thebottom cover412. Thefirst shaping element416 is deployed under tension along the Y-axis (seeFIG. 3), and it is tensed in order to cause thepad400 to curl upwardly in the direction of the Z-axis.

In one embodiment, thefirst shaping element416 is first secured to thebottom cover412 by a shaping element adhesive418, and second contained within aseam420 between thetop cover410 and thebottom cover412 by aconstruction adhesive422. In one embodiment, the shaping element adhesive418 is deployed by intermittent depositions along thepad400 along the Y-axis (seeFIG. 3). An intermittent deposition allows thetop cover410 and thebottom cover412 to form a gathered structure that can allow a substantially uniform pucker along the Y-axis of thepad400. In one embodiment, a continuous adhesive deposition along thepad400 is carried out.

In one embodiment, asurge element426 is disposed above the absorbentfirst element414. Thesurge element426 acts as a liquid intake and distribution layer. Thepad400 also includes an upper liner adhesive428 that can make contact with thesurge element426 if present, the absorbentfirst element414, and thebottom cover412. In one embodiment, the upper liner adhesive428 is formed in a swirl pattern, as is known in the art, to allow fluid to penetrate into thesurge element426 and the absorbentfirst element414. Thepad400 also includes a baffle adhesive430 that secures thebottom cover412 to the absorbentfirst element414. Thepad400 also includes agarment adhesive432 and arelease layer434 that protects thegarment adhesive432 prior to deployment.

In one embodiment, thepad400 also includes afirst web436 that acts as an envelope around the absorbentfirst element414. In one embodiment, thefirst web436 is a first tissue that is made of a material such as a liquid-absorbing wood fiber base. In one embodiment, thefirst web436 is an apertured material similar to the materials described for thetop cover110.

FIG. 5 is a cross section of a pad according to another embodiment. Thepad500 includes elements and structures similar to thepad400 depicted inFIG. 4, and some additional elements. Thepad500 is in an exploded configuration for clarity. Thepad500 includes a liquid-permeabletop cover510 and a liquid-impermeable bottom cover512. An absorbentfirst element514 is enclosed by thetop cover510 and thebottom cover512. Afirst shaping element516 is operatively associated with thetop cover510 and thebottom cover512. Thefirst shaping element516 is deployed under tension along the Y-axis (seeFIG. 3), and it is tensed in order to cause thepad500 to curl upwardly in the direction of the Z-axis (seeFIG. 2).

In one embodiment, thefirst shaping element516 is first secured to thebottom cover512 by a shaping element adhesive518, and second contained within aseam520 between thetop cover510 and thebottom cover512 by aconstruction adhesive522. In one embodiment, the shaping element adhesive518 is deployed by intermittent depositions along thepad500 along the Y-axis (seeFIG. 3). An intermittent deposition allows thetop cover510 and thebottom cover512 to form a gathered structure that can allow a substantially uniform pucker along the Y-axis of thepad500. In one embodiment, a continuous adhesive deposition along thepad500 is carried out.

In one embodiment, asurge element526 is disposed above the absorbentfirst element514. Thesurge element526 acts as a liquid intake and distribution layer. Thepad500 also includes an upper liner adhesive528 that can make contact with thesurge element526 if present, the absorbentfirst element514, and thebottom cover512. In one embodiment, the upper liner adhesive528 is formed in a swirl pattern, as is known in the art, to allow fluid to penetrate into thesurge element526 and the absorbentfirst element514.

Additionally thepad500 includes an absorbentsecond element538 and optionally, a surge element-absorbent second element adhesive540 disposed in a swirl pattern above the absorbentsecond element538. Adhesion of the absorbentsecond element538 to theoptional surge element526 can optionally be carried out by a perforation process that can include thetop cover510. The perforation process (not pictured) includes a perforation through selected elements that cause fibers or other structures of elements to intermesh with sufficient adhesion for ordinary use. Such perforation and intermeshing is known in the art.

Thepad500 also includes a baffle adhesive530 that secures thebottom cover512 to the absorbentfirst element514. Thepad500 also includes agarment adhesive532 and arelease layer534 that protects thegarment adhesive532 prior to deployment.

FIG. 6 is a cross section of a pad according to another embodiment. Thepad600 includes elements and structures similar to thepad500 depicted inFIG. 5, and some additional elements. Thepad600 is in an exploded configuration for clarity. Thepad600 includes a liquid-permeabletop cover610 and a liquid-impermeable bottom cover612. An absorbentfirst element614 is enclosed by thetop cover610 and thebottom cover612. Afirst shaping element616 is operatively associated with thetop cover610 and thebottom cover612. Thefirst shaping element616 is deployed under tension along the Y-axis (seeFIG. 3), and it is tensed in order to cause thepad600 to curl upwardly in the direction of the Z-axis (seeFIG. 2).

In one embodiment, thefirst shaping element616 is first secured to thebottom cover612 by a shaping element adhesive618, and second contained within aseam620 between thetop cover610 and thebottom cover612 by aconstruction adhesive622. In one embodiment, the shaping element adhesive618 is deployed by intermittent depositions along thepad600 along the Y-axis (seeFIG. 3). An intermittent deposition allows thetop cover610 and thebottom cover612 to form a gathered structure that can allow a substantially uniform pucker along the Y-axis of thepad600. In one embodiment, a continuous adhesive deposition along thepad600 is carried out.

In one embodiment, asurge element626 is disposed above the absorbentfirst element614. Thesurge element626 acts as a liquid intake and distribution layer. Thepad600 also includes an upper liner adhesive628 that can make contact with thesurge element626 if present, the absorbentfirst element614, and thebottom cover612. In one embodiment, the upper liner adhesive628 is formed in a swirl pattern, as is known in the art, to allow fluid to penetrate into thesurge element626 and the absorbentfirst element614.

Additionally thepad600 includes an absorbentsecond element638 and optionally, a surge element-absorbent second element adhesive640 disposed in a swirl pattern above the absorbentsecond element640. Adhesion of the absorbent second element adhesive640 to theoptional surge element626 can optionally be carried out in lieu of the surge element-absorbent second element adhesive640 by a perforation process that can include thetop cover610. The perforation process (not pictured) includes a perforation through selected elements that cause fibers or other structures of elements to intermesh with sufficient adhesion for ordinary use. Such perforation and intermeshing is known in the art.

Thepad600 also includes a baffle adhesive630 that secures thebottom cover612 to the absorbentfirst element614. Thepad600 also includes agarment adhesive632 and arelease layer634 that protects thegarment adhesive632 prior to deployment.

In one embodiment, thepad600 also includes asecond web642 that acts as an envelope around the absorbentsecond element638. In one embodiment, thesecond web642 is a second tissue that is made of a material such as a liquid-absorbing wood fiber base. In one embodiment, thesecond web642 is an apertured material similar to the materials described for thetop cover110.

FIG. 7 is a cross section of a pad according to another embodiment. Thepad700 includes elements and structures similar to thepad500 depicted inFIG. 5, and some additional elements. Thepad700 is in an exploded configuration for clarity. Thepad700 includes a liquid-permeabletop cover710 and a liquid-impermeable bottom cover712. An absorbentfirst element714 is enclosed by thetop cover710 and thebottom cover712. Afirst shaping element716 is operatively associated with thetop cover710 and thebottom cover712. Thefirst shaping element716 is deployed under tension along the Y-axis (seeFIG. 3), and it is tensed in order to cause thepad700 to curl upwardly in the direction of the Z-axis (seeFIG. 2).

In one embodiment, thefirst shaping element716 is first secured to thebottom cover712 by a shaping element adhesive718, and second contained within aseam720 between thetop cover710 and thebottom cover712 by aconstruction adhesive722. In one embodiment, the shaping element adhesive718 is deployed by intermittent depositions along thepad700 along the Y-axis (seeFIG. 3). An intermittent deposition allows thetop cover710 and thebottom cover712 to form a gathered structure that can allow a substantially uniform pucker along the Y-axis of thepad700. In one embodiment, a continuous adhesive deposition along thepad700 is carried out.

In one embodiment, asurge element726 is disposed above the absorbentfirst element714. Thesurge element726 acts as a liquid intake and distribution layer. Thepad700 also includes an upper liner adhesive728 that can make contact with thesurge element726 if present, the absorbentfirst element714, and thebottom cover712. In one embodiment, the upper liner adhesive728 is formed in a swirl pattern, as is known in the art, to allow fluid to penetrate into thesurge element726 and the absorbentfirst element714.

Additionally thepad700 includes an absorbentsecond element738 and optionally, a surge element-absorbent second element adhesive740 disposed in a swirl pattern above the absorbentsecond element738. Adhesion of the absorbentsecond element738 to theoptional surge element726 can optionally be carried out in lieu of the surge element-absorbent second element adhesive740 by a perforation process that can include thetop cover710. The perforation process (not pictured) includes a perforation through selected elements that cause fibers or other structures of elements to intermesh with sufficient adhesion for ordinary use. Such perforation and intermeshing is known in the art.

Thepad700 also includes a baffle adhesive730 that secures thebottom cover712 to the absorbentfirst element714. Thepad700 also includes agarment adhesive732 and arelease layer734 that protects thegarment adhesive732 prior to deployment.

In one embodiment, thepad700 also includes afirst web736 that acts as an envelope around the absorbentfirst element714. In one embodiment, thefirst web736 is a first tissue that is made of a material such as a liquid-absorbing wood fiber base. In one embodiment, thefirst web736 is an apertured material similar to the materials described for thetop cover110.

FIG. 8 is a cross section of a pad according to another embodiment. Thepad800 includes elements and structures similar to thepad700 depicted inFIG. 7, and some additional elements. Thepad800 is in an exploded configuration for clarity. Thepad800 includes a liquid-permeabletop cover810 and a liquid-impermeable bottom cover812. An absorbentfirst element814 is enclosed by thetop cover810 and thebottom cover812. Afirst shaping element816 is operatively associated with thetop cover810 and thebottom cover812. Thefirst shaping element816 is deployed under tension along the Y-axis (seeFIG. 3), and it is tensed in order to cause thepad800 to curl upwardly in the direction of the Z-axis (seeFIG. 2).

In one embodiment, thefirst shaping element816 is first secured to thebottom cover812 by a shaping element adhesive818, and second contained within aseam820 between thetop cover810 and thebottom cover812 by aconstruction adhesive822. In one embodiment, the shaping element adhesive818 is deployed by intermittent depositions along thepad800 along the Y-axis (seeFIG. 3). An intermittent deposition allows thetop cover810 and thebottom cover812 to form a gathered structure that can allow a substantially uniform pucker along the Y-axis of thepad800. In one embodiment, a continuous adhesive deposition along thepad800 is carried out.

In one embodiment, asurge element826 is disposed above the absorbentfirst element814. Thesurge element826 acts as a liquid intake and distribution layer. Thepad800 also includes an upper liner adhesive828 that can make contact with thesurge element826 if present, the absorbentfirst element814, and thebottom cover812. In one embodiment, the upper liner adhesive828 is formed in a swirl pattern, as is known in the art, to allow fluid to penetrate into thesurge element826 and the absorbentfirst element814.

Additionally thepad800 includes an absorbentsecond element838 and optionally, a surge element-absorbent second element adhesive840 disposed in a swirl pattern above the absorbentsecond element838. Adhesion of the absorbentsecond element838 to theoptional surge element826 can optionally be carried out in lieu of the surge element-absorbent second element adhesive840 by a perforation process that can include thetop cover810. The perforation process (not pictured) includes a perforation through selected elements that cause fibers or other structures of elements to intermesh with sufficient adhesion for ordinary use. Such perforation and intermeshing is known in the art.

Thepad800 also includes a baffle adhesive830 that secures thebottom cover812 to the absorbentfirst element814. Thepad800 also includes agarment adhesive832 and arelease layer834 that protects thegarment adhesive832 prior to deployment.

In one embodiment, thepad800 also includes afirst web836 that acts as an envelope around the absorbentfirst element814. In one embodiment, thefirst web836 is a first tissue that is made of a material such as a liquid-absorbing wood fiber base. In one embodiment, thefirst web836 is an apertured material similar to the materials described for thetop cover110.

In one embodiment, thepad800 also includes asecond web842 that acts as an envelope around the absorbentsecond element838. In one embodiment, thesecond web842 is a second tissue that is made of a material such as a liquid-absorbing wood fiber base. In one embodiment, thesecond web842 is an apertured material similar to the materials described for thetop cover110.

FIGS. 9A-9C are cross-section details of a shaping element or shaping elements according to various embodiments.

FIG. 9A illustrates a section of apad901 that includes atop cover910, abottom cover912, and afirst shaping element916. Thefirst shaping element916 is first secured to thebottom cover912 by at least one shaping element adhesive918,948,958, and968. In one embodiment, two of the disclosed shaping element adhesives are included. Alternatively, where two of the shaping element adhesives are disclosed, thefirst shaping element916 is contacted with shaping element adhesive on two sides in reference to the X-Z coordinates. In one embodiment, three of the disclosed shaping element adhesives are included. Alternatively, where three of the shaping element adhesives are disclosed, thefirst shaping element916 is contacted with shaping element adhesive on three sides in reference to the X-Z coordinates. In one embodiment, all four of the shaping element adhesives are included. Alternatively, where all four of the shaping element adhesives are disclosed, thefirst shaping element916 is contacted with shaping element adhesive on all four sides in reference to the X-Z coordinates.

FIG. 9B illustrates a section of apad902 that includes atop cover910, abottom cover912, and afirst shaping element916, and alast shaping element946. Thefirst shaping element916 and thelast shaping element946 are first secured to thebottom cover912 by at least one shaping element adhesive918,948,958,968,978,988, and998. Similar to the embodiment depicted inFIG. 9A, various embodiments include one of the shaping elements, or any combination of the shaping elements depicted inFIG. 9B. Alternatively similar to the embodiments depicted inFIG. 9A, at least one—and up to all of the surfaces of thefirst shaping element916 or thelast shaping element946 is contacted with a shaping element adhesive in reference to the X-Z coordinates.

FIG. 9C illustrates a plurality of more than two shaping elements. In this embodiment, however, as few as one shaping element is present. In one embodiment, afirst shaping element916 is accompanied by asubsequent shaping element956, and alast shaping element946. In one embodiment, adhesion of the shapingelements916,956, and946 includes at least one shaping element adhesive similar to the embodiments depicted inFIG. 9B.

In one embodiment, adhesion of the shapingelements916,956, and946 includes a heat process which at least partially fuses at least one of the shaping elements. In one embodiment, adhesions of the shapingelements916,956, and946 include a heat process which at least partially fuses at least one of the shaping elements, and the formation of shaping element adhesive according to the various embodiments set forth in this disclosure.

In one embodiment, such as the embodiments depicted inFIGS. 9B and 9C, the plurality of shaping elements are under tension differently from each other. In one embodiment, thefirst shaping element916 is under tension greater than thelast shaping element946. In one embodiment,last shaping element946 is under tension greater than thefirst shaping element916. By varying the tensions in the plurality of shaping elements, specific shaping can be achieved for the pad according to an application.

FIG. 10 is a process flow diagram according to an embodiment. It is noted in one embodiment that the shaping element adhesive is disposed above the shaping element (seeFIGS. 1 and 4-9). The shaping element adhesive, however, as set forth for the embodiments depicted inFIGS. 9A-9C, can be below the shaping element, or the shaping element adhesive can be on any and/or all sides of the shaping element depending upon the process that is selected for assembling a given pad.

Theprocess1000 implements the embodiments set forth herein. At1010, the process includes providing a top cover. At1020, the process includes providing a bottom cover. At1030, the process includes providing a shaping element according to the various embodiments set forth in this disclosure. At1040, the process includes folding the top cover and the bottom cover, in a single fold, after a manner that causes the shaping element to be enfolded with the top cover and the bottom cover in a direction toward the bottom cover. By “enfolded with the top cover and the bottom cover in a direction toward the bottom cover”, it is meant that the top cover and the bottom cover each have terminal edges beneath the pad.

Reference is made toFIG. 3. InFIG. 3, it can be seen that thetop cover310 has aterminal edge311 beneath thepad300. Similarly, thebottom cover312 has aterminal edge313 beneath thepad300. In another embodiment, “enfolded with the top cover and the bottom cover in a direction toward the bottom cover” means that a seam is formed beneath the pad. Reference is again made toFIG. 3. InFIG. 3, it can be seen that thetop cover310 forms aseam320 beneath thepad300.

In one process embodiment, the bottom cover is fed from a web such as a roll, and is first wrapped around the shaping element by a first folding mechanism. Thereafter, the top cover is conjoined with the bottom cover and is second wrapped around the shaping element by a second folding mechanism. In another process embodiment, the bottom cover and the top cover are substantially simultaneously folded by a single folding mechanism.

It is emphasized that the Abstract is provided to comply with 37 C.F.R. §1.72(b) requiring an Abstract that will allow the reader to quickly ascertain the nature and gist of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims

In the foregoing Detailed Description, various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate preferred embodiment

It will be readily understood to those skilled in the art that various other changes in the details, material, and arrangements of the parts and method stages which have been described and illustrated in order to explain the nature of this invention may be made without departing from the principles and scope of the invention as expressed in the subjoined claims.

Claims (20)

What is claimed is:

1. An article comprising:

a liquid-permeable top cover;

a liquid-impermeable bottom cover;

an absorbent first element enclosed by the top cover and the bottom cover; and

a first shaping element wherein the top cover and the bottom cover are folded over the first shaping element, and wherein at least one of the top cover and the bottom cover includes a terminal edge under the article.

2. The article according toclaim 1, wherein the first shaping element is first secured to the bottom cover, and second contained within a seam between a terminal edge of the top cover and portion of the bottom cover.

3. The article according toclaim 1, wherein the first shaping element is selected from an elastic member, a rigid member, a gathered portion of at least one of the top cover and the bottom cover, and a combination thereof.

4. The article according toclaim 1, wherein the absorbent first element is enclosed in a first web.

5. The article according toclaim 1, further including:

an absorbent second element above the absorbent first element, and below the liquid-permeable top cover.

6. The article according toclaim 1, further including:

an absorbent second element above the absorbent first element, and below the liquid-permeable liner, wherein the absorbent second element is enclosed in a second web.

7. The article according toclaim 1, further including:

a surge element disposed above the absorbent first element.

8. The article according toclaim 1, further including:

a surge element disposed above the absorbent first element; and

an absorbent second element above the absorbent first element, and below the liquid-permeable top cover, wherein the first shaping element is an elastic member that is first secured to the bottom cover, and second contained within a seam between the top cover and the bottom cover.

9. An article comprising:

a top cover including a first liquid permeability;

a bottom cover including a second liquid permeability, wherein the first liquid permeability is greater than the second permeability;

an absorbent first element enclosed by the top cover and the bottom cover; and

a first shaping element wherein the first shaping element is enfolded with the top cover and the bottom cover, and wherein at least one of the top cover and the bottom cover includes a terminal edge under the article.

10. The article according toclaim 9, wherein the top cover is liquid pervious, wherein the bottom cover is liquid impervious, and wherein the bottom cover is vapor pervious.

11. The article according toclaim 9, wherein the first shaping element is first secured to the bottom cover, and second contained within a seam between the top cover and the bottom cover.

12. The article according toclaim 9, wherein the first shaping element is selected from an elastic member, a rigid member, a gathered portion of at least one of the top cover and the bottom cover, and a combination thereof.

13. The article according toclaim 9, wherein the first shaping element is secured to the bottom cover by at least one selected from an adhesive, and a thermal weld.

14. The article according toclaim 9, further including:

at least one subsequent shaping element disposed adjacent the first shaping element, wherein the at least one subsequent shaping element is enfolded with the top cover and the bottom cover.

15. The article according toclaim 9, further including:

at least one subsequent shaping element disposed adjacent the first shaping element, wherein the at least one subsequent shaping element is enfolded with the top cover and the bottom cover, wherein the first shaping element is under a first tension, wherein the at least one subsequent shaping element is under a second tension, and wherein the first tension is greater than the second tension.

16. The article according toclaim 9, further including:

at least one subsequent shaping element disposed adjacent the first shaping element, wherein the at least one subsequent shaping element is enfolded with the top cover and the bottom cover, wherein the first shaping element is under a first tension, wherein the at least one subsequent shaping element is under a second tension, and wherein the second tension is greater than the first tension.

17. The article according toclaim 9, further including:

a surge element disposed above the absorbent first element; and

an absorbent second element above the absorbent first element, and below the liquid-permeable liner, wherein the first shaping element is an elastic member this is first secured to the bottom cover, and second contained within a seam between the top cover and the bottom cover.

18. The article according toclaim 9, further including:

at least one subsequent shaping element disposed adjacent the first shaping element, wherein the at least one subsequent shaping element is enfolded with the top cover and the bottom cover, and wherein the first shaping element and the at least one subsequent shaping element are secured by at least one of an adhesive thermal weld.

19. The article according toclaim 18, wherein the first shaping element is under a first tension, wherein the at least one subsequent shaping element is under a second tension, and wherein the first tension is greater than the second tension.

20. The article according toclaim 18, wherein the at least one subsequent shaping element is under a first tension, wherein the first shaping element is under a second tension, and wherein the second tension is greater than the first tension.

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